INSTALLATION
REPLACEMENT INFORMATION
REMOVING OLD CONTROL
1. | Turn off gas supply to the water heater at the manual gas |
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| water heater. |
2. | Locate the gas control valve/thermostat. Before performing |
| any maintenance, turn the temperature dial on the gas |
| control valve/thermostat to the lowest setting. (See To light |
| Appliance Figure 2) |
3. | On the top of the gas control valve turn the gas control |
| knob to the “Off” position. (See To light Appliance Figure A) |
| NOTE: On the |
| thermostat the knob stop must first be slightly |
| depressed before turning the gas control knob. |
4. | Close the cold water inlet valve to the water heater and |
| open a nearby hot water faucet. |
5. | Connect a hose to the drain valve and terminate it to an |
Gas supply 
pipe 
Gas
valve
Union
Tee
Drip leg
(sediment trap)
Pipe cap
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| LI | PIL | |
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| OT | |
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| GHTI | ||
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| N |
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| G |
Y |
| ER T OTH |
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R T |
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VEHO | RE ATWEEAS NCR | I | L | |
C | H TIW S | SOF KRIS | ||
G NI DLCA | C |
| O | |
B | :AUTION |
| W | |
| A |
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To pilot burner
To main burner
To thermocouple
| adequate drain. Open water heater drain valve by turning |
| handle counterclockwise to drain water heater tank. |
| IMPORTANT: DO NOT proceed to the following steps |
| until the water heater is completely drained. |
6. | On some water heaters, the outer door may need to be |
| removed. |
7. | If control doesn’t have a piezo ignitor, skip to step (8) or |
| disconnect the piezo ignitor wire from the piezo ignitor |
| button. |
| NOTE: There are two types of ignitors. If you have the |
| square ignitor, slide the ignitor bracket backward away |
| from the gas valve to remove it. If you have a round |
| ignitor, first remove the ignitor from the bracket by |
| depressing front and rear holding tabs and lift. Next |
| remove ignitor bracket from the gas valve. Keep ignitor |
| and bracket. |
8. | Disconnect the thermocouple, pilot tube, and manifold |
| (burner) tube. Some control may have two wires (flying |
| leads) attached to the thermal switch that must be |
| disconnected as well. |
9. | Disconnect the union joint in the gas piping. Disconnect the |
| remaining pipe from the gas control valve/thermostat. |
10. | Remove the control by turning it counterclockwise. If |
| needed, a short piece of ½” black iron pipe can be screwed |
| into the control inlet to increase leverage. |
INSTALLING NEW CONTROL
All piping must comply with local and state ordinances or with the National Fuel Gas Code (ANSI
Dirt or contamination in the gas line can block the control from operating creating a risk of explosion, injury or death. To protect the control from dirt/contamination, a drip leg or sediment trap (see Figure 1) must be installed in the piping to the control.
1.To replace the gas control valve/thermostat, reassemble in reverse order. When replacing the gas valve, use a short piece of pipe to help turn control. (Clockwise) DO NOT OVER TIGHTEN or damage may result. Use an approved pipe compound on the threads that screw into the tank and to the gas pipe that screw into the gas control valve/thermostat. Do not use TEFLON tape. Do not apply compound to first two threads on gas pipe.
2.Reconnect the gas piping to the gas control valve/ thermostat. Use new black iron pipe that has been properly reamed. If old pipe is used, be sure it is clean and free from rust and scale.
FigureFigure1. Typical1. gasconnection
3.If control had an ignitor, transfer the ignitor and bracket removed from the old gas control valve to the new one.
4.Reconnect manifold tube (burner), pilot tube, ignitor wire (if present), flying leads (if present), Thermocouple nut (thermocouple nut should be hand tightened and then turned an additional ¼ turn with small wrench. DO NOT OVERTIGHTEN. Do not use pipe joint compound or TEFLON tape on manifold, pilot, and thermocouple connections.
5.Reconnect union. DO NOT use joint compound or TEFLON tape on union connection.
6.Close the water heater drain valve by turning the handle to the right (clockwise). Open the cold water supply valve to the water heater to fill the water heater tank.
NOTE: The cold water supply valve must be left open when the water heater is in use.
Keep the nearby hot water faucet open for 3 minutes after a constant flow of water is obtained to purge the lines of any excess air. Check all new water piping for leaks. Repair as needed.
!CAUTION
Never use this water heater unless it is completely filled with water. To prevent damage to the tank, the tank must be filled with water. Water must flow from the hot water faucet before turning ON gas to the water heater.
7.Turn on gas shutoff valve.
!WARNING
DO NOT USE OPEN FLAME OR ANY KIND OF SPARK TO CHECK FOR LEAKS. Serious injury of death from fire or explosion could result.
8.BEFORE LIGHTING THE PILOT, CHECK THE GAS LINES FOR LEAKS. Use a soapy water solution. DO NOT test for gas leaks using a match or open flame.
Brush the soapy water solution on all gas pipes, joints, and fittings. Check for bubbling soap indicating you have a leak. Turn OFF the gas and make the necessary repairs. Recheck for leaks. Rinse off soapy solution and wipe dry.
9.Affix the new Lighting instruction label on the water heater to cover the existing label.
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